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PPAP Submission Checklist 6/12/07 Rev A

PPAP Submission Checklist

Part Number Supplier

Description Submission Date

Rev. Level PPAP Level

ApprovalTAB AIAG # PPAP Requirement Date Approver

1 18 Comments:2 1 Comments:3 2 Comments4 3 Comments:5 4 Comments:6 5 Comments:7 6 Comments:8 9 Comments:9 10 Comments:

10 11 Comments:

11 8 Comments:

12 12 Comments:

13 7 Comments:

14 13Comments:

15Comments:

16 14Comments:

17 15Comments:

18 16Comments:

19Comments:

20Comments:

21Comments:

22Comments:

23Comments:

24Comments:

PPAP Warrant (Last document approved in submission package)

Design Records

Engineering Change Documentation

Customer Engineering Approval (if required)

Design FMEA

Process Flow Diagram

Process FMEA

Dimensional Results

Material, Performance, Test Results

Initial Process Study

Measurement Systems Analysis Studies

Qualified Laboratory Documentation

Control Plan/ Work Instructions/ Visual aides

Appearance Approval Report (AAR) (if required)

Bulk Material Requirements Checklists (for bulk material PPAP only)

Sample product (SRG Global retain)

Master Sample (Supplier retain)

Checking aides, fixtures, test stands, Mylar (if applicable)

IMDS/RSMS evidence

NAFTA/Certificate of Origin (North America Requirement Only)

Contingency Plans/ Lot Control & Traceability

Process Approval/ Run@Rate

Packaging/ Ship labels

Sub Supplier PPAP has been approved by the Supplier

PPAP tab 1 6/12/07 Revision A

PPAP Submission Checklist Tab 1




Completed Part Submission Warrant Yes No N/A

1 & 2 The part name and part number are correct as recorded on this warrant

Comments:3 Shown on Drawing #: Is the drawing that specifies the customer part # being submitted. Comments:4 The engineering level is correct and the correct date Comments:5 Additional engineering changes have been identified correctly *Authorized Changes not yet incorporated in drawing but in part*

Comments:

6 The safety item box is marked correctlyComments:

7 The Supplier Quote matches the SRG Global Purchase Order and meets all print requirements. * Supplier to verify with SRG Global purchasing group *Comments:

8 Comments:9 Checking Aid No.: Enter check aid number if applicable.

Comments:10 Engineering Change Level: Identify current revision and approval date. Comments:

11 Comments:

12 Comments:

13-16 Submission Information: Has been completed. (#16 if available) Comments:

17 Reason for submission has been completed. Comments:

18 The PPAP is at the Requested Submission Level per SRG Global instructionsComments:

19-20 Submission Results pass and have been completed.Comments:

21-22 The declaration has been properly completed and signed by an appropriate supplier representative.

Comments:

N/A 0

REJECTED 0Date Reviewed S

Reviewed By S COMPLETED 0

Part Weight: Enter the actual part weight in kilograms to four decimal places

Supplier Name & Code: Show the code assigned to the mfg location on the PO.

Supplier Mfg Address: Is where the product was manufactured.

PPAP tab 1 Warrant 6/12/07 Revision A

Part Submission Warrant

Part Name Cust. Part Number

Shown on Drawing No. Org. Part Number

Engineering Drawing Change Level Dated

Additional Engineering Changes Dated

Safety and/or

Government Regulation Yes No Purchase Order No. Weight (kg)

Checking Aid No. Engineering Change Level Dated

ORGANIZATION MANUFACTURING INFORMATION CUSTOMER SUBMITTAL INFORMATION

Organization Name & Supplier/Vendor Code Customer Name/Division

Street Address Buyer/Buyer Code

City Region Postal Code Country Application

MATERIALS REPORTINGHas customer-required Substances of Concern information been reported? Yes No n/a

Submitted by IMDS or other customer format:

Are polymeric parts identified with appropriate ISO marking codes? Yes No n/a

REASON FOR SUBMISSIONInitial Submission Change to Optional Construction or Material

Engineering Change(s) Sub-Supplier or Material Source Change

Tooling: Transfer, Replacement, Refurbishment, or additional Change in Parts Processing

Correction of Discrepancy Parts Produced at Additional Location

Tooling Inactive > than 1 year Other - please specify

REQUESTED SUBMISSION LEVEL (Check one)Level 1 - Warrant only (and for designated appearance items, an AppearanceApproval Report) Submitted to customer.

Level 2 - Warrant with product samples and limited supporting data submitted to customer.

Level 3 - Warrant with product samples and complete supporting data submitted to customer.

Level 4 - Warrant and other requirements as defined by customer.

Level 5 - Warrant with product samples and complete supporting data reviewed at suppliers manufacturing location.

SUBMISSION RESULTSThe results for dimensional measurements material and functional test appearance criteria statistical

These results meet all design record requirements: Yes No (If "No" - Explanation Required)

Mold / Cavity / Production Process __________________________DECLARATIONI affirm that the samples represented by this warrant are representative of our parts, and have been madeby a process that meets all Production PartApproval Process Manual 4th Edition Requirements. I further affirm that these samples were produced at the rate of _____ / ___ hours.I also certifiy that documented evidence of such compliance is on file and available for review. I have noted any deviations from this declaration below.EXPLANATION/COMMENTS:

Is each Customer Tool properly tagged and numbered? Yes No n/a

Organization Authorized Signature Date

Print Name Phone No. FAX No.

Title E-mail

FOR CUSTOMER USE ONLY (IF APPLICABLE)PPAP Warrant Disposition Approved Rejected Other

Customer Signature Date

Print Name Customer Tracking Number (optional)






Completed Drawing (Design) Record Checklist Yes No N/A

1 The drawing or design record is correct and at the proper engineering/rev

level and matches P.O. Comments:

2 Are all dimensions including notes ballooned on the drawing?Comments:

3 All noted specs are at the latest revision to SRG Global records.Comments:

4 A copy of the specs are included with the PPAP.Comments:

5 For bulk materials, is the raw material properly identified? With formula? *example: resin, paint etc.* Comments:

N/A 0

NO - REJECTED 0Date Reviewed SReviewed by S COMPLETED 0





Completed Engineering Change Document Checklist Yes No N/A

1 There are authorized engineering changes not yet recorded in the drawing. *Customer Signed Approved Red Marked Up Drawing Required along with change documents*

Comments:

2 This submission includes an approved Supplier Request for Product Change.Comments:

N/A 0



PPAP tab4 6/12/07 Revision A




Completed Customer Engineering Approval Checklist Yes No N/A

1 There is evidence of customer engineering approval where specified. Comments:2 Any/all engineering changes are clearly described and identified. Comments:3 If needed there is an approved Deviation Request included in this PPAP. Comments:4 Any/all process changes are clearly described and identified. Comments:5 Any/all sub-contractor changes are clearly described and identified.

Comments:6 There are no Engineering approvals required for this PPAP.

Comments:

N/A 0







Completed Design FMEA Checklist Yes No N/A

NOTE: If SRG Global is design responsible for the DFMEA and does not supply it to the supplier, the supplier must review this with SRG Global.It is the policy of SRG Global not to release hard copies.

1 The supplier is Design Responsible for the product in this PPAP.If not, place "Not Applicable" and refer to above note.

Comments:

2 The DFMEA was developed and reviewed for this PPAP package. Comments:

3 The DFMEA was prepared using current AIAG guidelines. Comments:

4 Historical campaign, lessons learned, warranty data etc. were reviewed for this DFMEA.

Comments:

5 Similar DFMEA's have been considered. Comments:

6 Design characteristics that affect high risk priority failure modes are identified.Comments:

7

Comments:

8 High risk priorities have been revised when corrective actions have been completed and verified.

Comments:

9 Where required, SRG Global and/or the Customer have reviewed and accepted the DFMEA Comments:

10 Significant Characteristics are identified and captured within the DFMEA.Comments:

N/A 0



Appropriate corrective actions have been taken/planned for high severity numbers and risk numbers were revised when design change was completed.





Completed Process Flow Diagram Checklist Yes No N/A

1 The Flow Diagram is keyed or numbered and illustrates the sequence

of production and inspection from receiving through shipping.Comments:

2 Available FMEA's were used to aid in develop of the flow diagram. Comments:

3 The flow diagram describes how product will be safely moved from station to station.

Comments:

4 The flow diagram describes where and how product will be stored. Comments:

5 Significant Dimensions have been identified at each appropriate station.Comments:

6 Do all operations, including significant characteristics follow a sequential order thru DFMEA (where applicable) PFMEA, Process Flow and

Control Plan.Comments:

N/A 0

NO - REJECTED 0

Date Reviewed SReviewed by S COMPLETED 0







Completed Process FMEA Checklist Yes No N/A

1 Was the process FMEA prepared per current AIAG guidelines. * (RPN's, Format etc.) *

Comments:

2 All operations affecting fit, form and function, durability, governmental regulations and safety have been identified and listed sequentially. Stations where safety is affected are properly identified on PFMEA.

Comments:

3 Similar part PFMEA's, Lessons Learned, Historical Campaign, Customer Plant Problems, Warranty Data and Equipment were reviewed and considered.

Comments:4 Appropriate corrective actions have been taken/planned for high RPN ratings.

Comments:

5 Have process parameters been considered for potential failure modes.Comments:

6 The PFMEA is keyed to the Flow Diagram and matches the sequential numbers.

Comments:

7 Where needed, have poka yoke-error mistake proofing methods been implemented and verified they will adequately protect the next operation.

Comments:

8 Do all operations, including significant characteristics follow a sequential order thru DFMEA (where applicable) PFMEA, Process Flow and Control

plan.Comments:

9 An effective preventive maintenance plan has been considered and implemented for all production equipment.

Comments:

N/A 0

NO - REJECTED 0Date Reviewed SReviewed By S COMPLETED 0





Completed Dimensional Results Checklist Yes No N/A

1 The dimensional results address all ballooned features on the drawing including notes.

Comments:

2 All dimensional results indicate the product conforms with specification. Comments:

3 The dimensional report includes data for parameters, including notes. Comments:

4 Any/all exceptions are identified and have SRG Global/ Customer approval. Comments:

5 The dimensional report includes date, rev. level, part number and inspector.Comments:

6 The dimensional report defines the measurement techniques used for eachmeasurement. Where go no/go criteria is used, the check fixture, test.

7 stand, or other equipment is identified and approved by customer for use. Comments:

8 Significant/Critical characteristics are in bold print and easily found on report.Comments:

9 All dimensions on the layout using table (default) tolerances have been verified.

Comments:

10 Material callouts, specifications, notes are all referenced on the dimensional report and attachments are enclosed as needed. Comments:

11 There are features not to print (NTP), but customer engineering approval is included for each NTP feature and an action plan is also included where

required.Comments:

12 For multicavity tooling, at least 2 pc per cavity must have a complete layout performed or as requested.

Comments: SEE THE FOLLOWING TAB 8 DIM SHEET FOR EXAMPLE N/A 0

NO - REJECTED 0



March CFG-1003 2006

Production Part ApprovalDimensional Test Results

ORGANIZATION: SRG Global PART NUMBER: 0SUPPLIER / VENDOR CODE: SUPPLIER MANUFACTURING SITE PART NAME: 0INSPECTION FACILITY: DESIGN RECORD CHANGE LEVEL: 30-12-99

ENGINEERING CHANGE DOCUMENTS:

ITEM OK NOT OK1 2 3 4 5 6

Blanket statements of conformance are unacceptable for any test results.

SIGNATURE TITLE DATE

DIMENSION / SPECIFICATION

SPECIFICATION / LIMITS

TEST DATE

ORGANIZATION MEASUREMENT RESULTS (DATA)





Completed Material Performance, Test Results Checklist Yes No N/A

1 All tests have been performed for all parts, product materials as defined on the drawing and/or control plan. (A table of contents should be included to identify the tests included) Comments:

2 The quantity tested and the actual results of each test are listed in a convenient format referencing the test specification/ requirement. A copy of the specification is included. Comments:

3 The record includes the rev. level of the parts tested, the date and changelevel of all specifications and a description of the test method/ test equipment used to conduct the test.Comments:

4 If testing was performed by a subcontractor, the name, address, contact information and supplier code number for the material from the customer-

approved subcontractor list. (where required)Comments:

5 Performance tests were conducted and the results of each test are listed in a convenient format. (A table of contents should be included to identify the tests included) Comments:

6 PV testing has been completed? Comments:

7 All test results indicate each test has successfully met the test criteria Comments:

8 Engineering approval is included for any/all tests that did not pass, wereconducted in an alternate test method, were conducted in an unapproved

test laboratory or anywhere tests were excluded or waived.Comments:

9 Raw material meets all print requirements and the certification has been included with in the PPAP.Comments:

10 Regrind percentage (If applicable) has been identified and agreed to by SRG Global (Provide Documentation).Comments:

N/A 0



March CFG-1004 2006

Production Part ApprovalMaterial Test Results

ORGANIZATION: SRG Global PART NUMBER: 0SUPPLIER / VENDOR CODE: SUPPLIER MANUFACTURING SITE PART NAME: 0

MATERIAL SUPPLIER: DESIGN RECORD CHANGE LEVEL: 30-12-99*CUSTOMER SPECIFIED SUPPLIER / VENDOR CODE: ENGINEERING CHANGE DOCUMENTS:

*If source approval is req'd, include the Supplier (Source) & Customer assigned code. NAME of LABORATORY:

MATERIAL SPEC. NO. / REV / DATE SUPPLIER TEST RESULTS (DATA) OKSPECIFICATION / LIMITS

TEST DATE

QTY. TESTED

NOT OK

March CFG-1004 2006

Production Part ApprovalMaterial Test Results

ORGANIZATION: SRG Global PART NUMBER: 0SUPPLIER / VENDOR CODE: SUPPLIER MANUFACTURING SITE PART NAME: 0

MATERIAL SUPPLIER: DESIGN RECORD CHANGE LEVEL: 30-12-99*CUSTOMER SPECIFIED SUPPLIER / VENDOR CODE: ENGINEERING CHANGE DOCUMENTS:

*If source approval is req'd, include the Supplier (Source) & Customer assigned code. NAME of LABORATORY:

MATERIAL SPEC. NO. / REV / DATE SUPPLIER TEST RESULTS (DATA) OKSPECIFICATION / LIMITS

TEST DATE

QTY. TESTED

NOT OK

Blanket statements of conformance are unacceptable for any test results.

SIGNATURE TITLE DATE





Completed Initial Process Study Checklist Yes No N/A

1 The initial process studies were conducted using the required number of samples and using production processing, gauging and materials. (Verify for all features requiring process studies comply) Comments:

2 The studies were conducted on PPAP samples and use PpK as the index. Comments:

3 The studies were conducted using production level parts CpK is the index. Comments:

4 The studies were conducted using AIAG approved attribute studies. Comments:

5 The supplier has identified any/all unstable processes and has submittedcorrective actions approved by customer. NOTE: Approval must be obtainedprior to any submission.

Comments:

6 The process has a one-sided specification or non-normal distribution and alternative acceptance criteria was approved by the customer. Comments:

7 Acceptance criteria has been satisfied and data indicates all studies comply. (PpK- 1.67 CpK- 1.33 per current AIAG guidelines or as approved by

customer) Comments:

8 Acceptance criteria has not been satisfied and customer approval and thecorrective action plans are included.

Comments:

N/A 0








Completed Measurement Systems Analysis Studies Checklist Yes No N/A

1 The PPAP package contains pictures, drawings, sketches, etc.

describing gages. Comments:

2 The supplier has a proper calibration system in place where all gagesare tracked and evidence is readily available as required.

Comments:

3 Standard test methods; ASTM, ISO, AMS, etc. were followed. Comments:

4 All gage calibrations are traceable to the appropriate regional standard.such as NIST etc.

Comments:

5 Gage Repeatability and Reliability Studies were conducted per current AIAG criteria. However, if one or more of the studies does not indicate compliance with AIAG guidelines, customer acceptance / approval must be enclosed. (All Gages Inclusive)

Comments:

N/A 0

NO - REJECTED 0







Completed Qualified Laboratory Documentation Checklist Yes No N/A

1 All testing for this PPAP was performed at TS 16949/ A2LA or equivalent accredited laboratories or laboratories approved by the

customer. (see #4 & 5) (Attach evidence for customer-approved laboratories) Comments:

2 This PPAP includes documented evidence of the scope of accreditation demonstrating the laboratory complies with TS 16949/A2LA

or equivalent requirements. Comments:

3 This PPAP includes customer approval for any/all testing performed atlaboratories that do not comply with TS 16949.Comments:

4 If any internal testing has been completed, the supplier laboratory must becovered under their TS16949 or equivalent certification.Comments:

5 If outside testing is required, the laboratory must be A2LA or equivalentcertified.Comments:

N/A 0

NO - REJECTED 0







Completed Control Plan/ Work Instructions/ Visual Aides Checklist Yes No N/A

1 Were current AIAG guidelines used to develop this Control Plan. Comments:

2 The control plan is keyed to the flow diagram, PFMEA and is matched to the sequential numbers in both of those documents.(incoming thru shipping) Comments:

3 The control plan has clear and easily viewed identification of significant or critical controls, safety items, government compliance and regulatory. Comments:

4 All special product/process characteristics are included in the control plan. Comments:

5 For significant characteristics, is SPC the control method for production process monitoring?

6 The DFMEA was used to prepare this control plan where applicable. Comments:

7 The PFMEA was used to prepare this control plan. Comments:

8 Drawing specifications requiring inspection are identified and addressed. Comments:

9 Engineering performance testing requirements identified and addressed. Comments:

10 This control plan covers all activities from receiving inspection to shipment. Comments:

11 Gages and test equipment are available as required in the control plan. Comments:

12 Are gages and controls compatible between supplier and customer.For Example: correlation studies etc.

Comments:

13 Visual aides and Work Instructions are included in the PPAP as needed. Comments:

14 Customer approval of the control plan is included in this PPAP if required. Comments:

15 The control plan includes annual PPAP requirements per SRG Global Supplier Manual Comments: N/A 0


Comments:






Completed Appearance Approval Report Checklist (Components Only) Yes No N/A

1 There is a color or appearance specification identified on the design record Comments:

2 The appearance specification requires submission of the AIAG Appearance Approval Report (AAR) as described in the PPAP manual 4th edition. This report is included in this PPAP. Comments:

3 The formal AIAG AAR is not required, but evidence is included in this PPAP demonstrating compliance to the color or visual specification noted on the design record. Comments:

4 No color or appearance requirements are identified on the design record. Comments:

Appearance Approval Report Checklist (Coiled Metal/Aluminum Only)

5 Part has been identified as a Class "A" surface part?Comments:

6 Proper Customer performance specification outlined on the drawing? Comments:7 AAR Sign off by SRG Prog. Mgr, Plant Manager, AAR Lead and Supplier Quality? Comments:8 Customer AAR Approval given? (3 Samples 1 for Customer, SRG and Supplier) Comments: All applicable AAR approvals must be granted before full PPAP is granted and before the Supplier

is allowed to ship material for production.

N/A 0

NO - REJECTED 0







Completed Bulk Materials Requirements Checklist-Example: Resin, Paint Etc. Yes No N/A

1 The material being submitted is included on any/all customer approved lists and evidence is included in this PPAP. (Attach a copy of the list/ or identify the reference page and location of approved material in customer list) Comments:

2 This PPAP meets all requirements identified in the Bulk Material Addendumof the current AIAG criteria. PPAP manual Appendix F and the checklist is included

Comments:

3 For bulk material, where required, there is a Design Matrix included.Per current AIAG addition criteria.Comments:

N/A 0

NO - REJECTED 0


S






Completed Sample Product Checklist-Retained at SRG Global Yes No N/A

1 The required number of samples have been submitted to the customer as required in the P.O. or in the customer requirements manual. (For single cavity tooling, default is 300 pc. run with 5pcs. + sectioned parts

as required)(For multi cavity tooling, default is 300 pc. run with 2 pc per cavity + sectioned parts as required)

Comments:

2 Samples were identified, packaged and submitted to customer as required. Comments:

3 Samples will be kept in a product safe environment for a period as defined in the current AIAG PPAP manual. Comments:

N/A 0

NO - REJECTED 0






Completed Master Sample Checklist-Retained at the Supplier Yes No N/A

1 The Master Sample for this PPAP will be retained for the same period of time as the PPAP records or until a new master sample is produced for the same customer part number for customer approval. Comments:

2 The master sample is identified with approval date and any reference info required to allow correlation with the PPAP package and the related PPAP data and records. Comments:

3 A master sample is available for each cavity of the tool if required. Comments:

N/A 0

REJECTED 0







Completed Checking Aides, fixtures, test stands, Mylar Checklist Yes No N/A

1 All product specific checking aides, fixtures, test stands and Mylar have been listed in this PPAP submission along with qualification data for each of those devices. Comments:

2 The supplier has certified that all aspects of each of these devices agree with part dimensional requirements and are properly listed where applicable on the control plan. Comments:

3 All engineering changes have been incorporated into the checking aides.Comments:

4 The supplier has provided for preventive maintenance for the checking aides.

Comments:

5 The supplier has included these checking aides in the gage R&R studies identified in Tab11 of this PPAP submission. Comments:

N/A 0







Completed IMDS/RSMS Evidence/Compliance Checklist Yes No N/A

1 Where required, OEM customer specific requirements for Substance Use are documented in this PPAP. EXAMPLE: Statement of conformance to Ford WSSS-M99P9999-A! Comments:

2 Where required, plastic parts are identified with the proper ISO symbol. Comments:

3 The OEM IMDS database for tracking restricted and hazardous materials has been updated to include all materials used to produce the PPAP

samples. Evidence of successful loading of the database is enclosed. Comments:

4 Customer specific database criteria has also been met; such as Ford. RSMS. Comments:

5 For European customer parts, End of Vehicle Life requirements have been satisfied and evidence is enclosed in this PPAP. Comments:

PPAP Approval CAN NOT be granted until ALL items in this section are fully satisfied and documented. Submit to SRG Global IMDS #9949 & 3905.

N/A 0

NO - REJECTED 0

Date Reviewed SReviewed By S COMPLETED 0







Completed NAFTA/Certificate of origin (North America Requirement Only) Yes No N/A

1 The certificate of origin for each part has been provided Comments:

2 The proper certificate has been completed? For Materials made in U.S., Canada and Mexico complete the NAFTA CertificateCBP form 434.

For Materials made outside U.S., Canada and Mexico complete the Non-NAFTA Certificate of Origin.If you are a distributor only, fill out the distributor affidavitComments:

3 The documentation has been properly signed? Comments: 4 The documentation has been sent to Intertrade Law for review? Comments: 5 I have included a copy of the part print and specifications with my

NAFTA form so the classification can be verified. Comments: 6 I have received confirmation from Intertrade Law that my certificate has

been accepted. Proof included with PPAP. Comments: *NOTE* If you have questions or concerns about this documentation please contact Megan Cummings at (954) 942-2114; fax (954) 514-9022; email: [email protected]. You must

email the completed NAFTA form, print and Material Certificate of Analysis to Megan Cummings for review. Once approved she will send an email confirmation of approval. At aminimum the email cofirmation from Intertrade law

to your company stating your documents have been received, reviewed and approved must accompnay this PPAP.

N/A 0

NO - REJECTED 0Reviewed By S

S COMPLETED 0

At a minimum an

Date Reviewed

Decision Tree NAFTA 434 Form

Non-NAFTA Certificate

Distributor Affidavit






Completed Contingency Plan/ Lot Control & Traceability Checklist Yes No N/A

1 The guidelines for the AIAG M-12 criteria have been satisfied Comments:

2 The lot control/traceability process for this product has been prepared and is included in this PPAP and has been approved by the customer where required. Comments:

3 The supplier has tested the lot control/traceability system and the results are enclosed in this PPAP.

Comments:

4 An Emergency Contact has been included in this PPAP and includesoff hours contact information.

Comments:

N/A 0

NO - REJECTED 0Date Reviewed SReviewed By S COMPLETED 0






Completed Process Approval/ Run@Rate Checklist Yes No N/A

1 The Run@Rate or equivalent process trial run has been completed and has demonstrated the supplier's ability to meet all quoted capacity and quality requirements. Comments:

2 The Run@Rate study was based on a significant production run as agreed upon with the customer. Comments:

3 Any/all unexpected quality fallout has been evaluated and reflected in the PFMEA and Control Plan. (regardless of failure rate) Comments:

N/A 0

NO - REJECTED 0

Date Reviewed SReviewed By S COMPLETED 0

Preliminary PPAP tab 22 R@R review 6/12/07 Revision A

Run @ Rate Summary Part Description Part #Shipping DestinationSupplier/ Mfg. Location Chg. Level

Quoted Production Rate /hr /day

Customer Buyer Phone#

Daily Weekly SQEPhone#

Planned Run @ Rate

Planned Hours to Run/hr

Planned Shifts/shift

Reason for Planned Downtime/day

RESULTSActual Hours From To

/hrActual Shifts Date

/shiftActual Downtime hours (Planned and Unplanned)

Explain: /day

Total Produced - Total Rejected = Net

Planned Usage:

Goal (net good parts)

Planned Downtime

ACTUAL (net good parts)


Run @ Rate Review WorksheetSupplier Name: Part Number(s):

RUN @ RATE REVIEW CONTENTDuring the Run @ Rate, the following shall be reviewed:DocumentationManufacturing process and resultsPart quality requirements and resultsSub-supplier requirementsRun @ Rate resultsPackaging, labeling and handling processes (dock to dock)

7.1. DocumentationAt the time of the Run @ Rate, the following support documentation should be available for review:

Available YES/NO7.1.1. Appropriate PPAP package information7.1.2. Quoted tool capacity and planned machine loading information

7.1.3. Operator/inspection instructions7.1.4. Prototype/pilot concerns7.1.5. Sub-contractor control/capacity planning process7.1.6. Sub-contractor material schedules and transportation plan for production

7.1.7. Packaging/labeling plan for production7.1.8. Acceleration plan / Early production containment

7.2. Manufacturing Process RequirementsYES/NO

7.2.1.

Comments:

7.2.2.

Comments:

7.2.3. Are operator instructions/visual aids available and adhered to at each workstation?

Comments:0

7.0 RUN @ RAT

Is the product being manufactured at the production site using the production tooling, gaging, process, materials, operators, environment, and process settings?

Does the actual process flow agree with the process flow diagram, as documented in PPAP? (Review the facility plan and layout. Walk the process with the flow diagram.)


7.2.4.

Comments:0

0

0

7.2.5.

Comments:

7.2.6.

Comments:

7.3. Manufacturing Capacity ResultsThe following shall be verified during the Run @ Rate. (With Planned Machine Loading)

YES/NO7.3.1. Can net output from each operation support quoted tool capacity?

Comments:

Operation Quoted Capacity Rate

YES/NO7.3.2.

Comments:

Is all in-process documentation, such as process control charts, in place at the time of the Run @ Rate? Is the documentation utilized to drive a defined reaction plan and corrective action process?

When required, are production boundary samples available at required workstations? Does SRG Global systems approve the boundary samples?

Are maintenance plans in place? Are repair and maintenance parts available? Is there planned downtime for preventative maintenance?

During the Run @ Rate, did the tooling meet the quoted up time requirements (net vs. gross quoted output)? Make note of any unexpected downtime and corrective action plans required.


7.3.3. Can all line changeovers, if any, be performed within the quoted tool capacity requirements?

Comments:

7.3.4.

Comments:

7.3.5. Is the acceleration plan sufficient to meet SRG Global's requirements?Comments:

7.4. Part Quality Plan VerificationYES/NO

7.4.1.

Comments:

7.4.2. Are all in process gaging and controls complete, functional and in place?

Comments:

7.4.3.

Comments:

7.4.4.

Comments:

7.4.5.

Comments:

7.5. Part Quality Results

Does the net throughput of good pieces (scrap taken out, any allowable rework) meet daily quoted tool capacity?

Are all production checking fixtures complete, with acceptable measurement system studies (e.g., gage R and R) performed, and operator instructions/visual aids available?

Do the process control plans (production and pre-launch) agree with the actual process? Do production part checks and statistical monitoring take place as outlined on the process control plan?

Are potential failure modes, as identified in the PFMEA, addressed through error proofing or the control plan?

Do the process control plan's reaction plan and the supplier's process for containment and corrective action ensure effective containment and correction?


YES/NO

Is there a plan in place to track, analyze, and improve First Time Quality?

If NO, then what is the date for implementation?

Comments:

7.6. Subcontractor RequirementsYES/NO

7.6.1.

Comments:

7.6.2. Are controls in place to isolate incoming material until it has been approved?

Comments:

7.7. Packaging, Labeling, and HandlingYES/NO

7.7.1.

Comments:

7.7.2.

Comments:

7.7.3. Is all material properly identified with appropriate label information?

Comments:

7.7.4. Does the supplier's labeling system ensure that no misidentification will occur?

Comments:

7.7.5. Is bar code labeling a requirement unless specifically instructed otherwise by purchasing?

Do the parts produced off production tooling during the Run @ Rate meet SRG Global's requirements for on-going quality?

Were subcontractors' abilities to meet defined quality and capacity requirements confirmed by the supplier prior to the Run @ Rate? Was verification of the subcontractors' manufacturing processes accomplished through a Run @ Rate or similar process condu

Do the in process and final shipment packaging preserve part quality and provide for easy loading and unloading of parts?

Does the supplier's method for in process and final shipping packaging and handling effectively eliminate the potential for process errors or mixed stock?


Comments:

Additional COMMENTS:

Phone: Date:

Guidelines for Pass, Open, & Fail Quality Results

All of the preceeding requirements must be met to pass the Run @ Rate.

Pass - The manufacturing process agrees with the manufacturing & quality plan as documented in PPAP.

- The quality system was documented and practiced. - An effective & documented FTQ plan is in place. - No open issues.

Open - Minor nonconformity(s) exist but will not likely result in the shipment of nonconforming material.

- FTQ plan not documented. - Open issues exist.

Fail ReRun Date: ______________

- Major nonconformities exist that may result in the shipment

of nonconforming products. - The manufacturing process does not agree with the manufacturing & quality plan as documented in PPAP.

- The absence or total breakdown of a quality system.

Plant Launch Team leader :____________________________ Date:________________

Supplier Concurrence: _____________________________Date: ______________

Completed By:

- One or more 'No' answers in the Review Worksheet.

PPAP tab 22 R@R form 6/12/07 Revision A

SRG Global Run @ Rate Calculation Form

REV 03/2004

Supplier Name: Part Numbers(s):

CAPACITY PIECES PER HOUR UPTIME (TRS) FTQ (first time Gross DAILY CAPACITY CALCULATIONS Observationquality) Hours Planned Planned Actual Worst Excess Period

QTC MSV Mach. Cycle / Hr. Pieces # Total Hrs. Machine Case or Net GoodOperation (per day) (per day) Planned Actual / Cycle Planned Actual Planned Actual Sh Day Useage (EGHJMN) (FGIKMN) Time Pieces

0 0 0 00 0 0 00 0 0 00 0 0 00 0 0 00 0 0 0

0 0 0 00 0 0 0

0 0 0 00 0 0 0

0 0 0 00 0 0 0

0 0 0 00 0 0 00 0 0 00 0 0 00 0 0 0

A B C D E F G L M O P Q R S T

NOTES: Productive Hours: Hrs. per Shift1.) Planned Capacity - Calculated by Operation; however, may be limited by sequential process operation (i.e.: preceeding process) Start-up/Changeover

Lunch2.) Actual Equivalent - Based on supplier's actual / observed performance (e.g.: Cycle, Uptime, FTQ, etc.). Maintenance

0.0 Net Hrs. per Shift3.) Worst Case Equivalent - Calculated as the lesser value of either planned or actual for all applicable elements (e.g.: Machine Cycle, Uptime, and FTQ) Shifts per day

and parts entering each sequential step. 0.0 Hours/dayWork Days / Year

4.) Excess or Shortage - Based on Actual Daily Equivalent; compared to the greater of either Quoted or Required Capacity (C/D).

5.) Percentages: All percentages (H,I,J,K,N) are input as they should appear (I.e.: 94.7% should be input as 94.7); NOT as a decimal (e.g.: 0.947).

Capacity1 Equivalent2

Equivalent3 Shortage4

H5 I5 J5 K5 N5






Completed Packaging/ Shipping Label Submission Checklist Yes No N/A

1 Packaging has been tested and verified and where required, approved by the customer. (approval enclosed from purchasing and manufacturing site) Comments:

2 Packaging designs, drawings, and data are included in the PPAP Comments:

3 An expendable or temporary package has been tested and approved by the customer as a contingency measure. Details for that package are also enclosed in this PPAP. Comments:

4 A sample of the shipping label is enclosed and has been accepted by thecustomer based on scanning and test reading the label.(New Suppliers Only)

Comments:

N/A 0

NO - REJECTED 0


SRG Global Packaging and Freight FormSupplier Information Contact Information

Supplier Name: Packaging Contact:Supplier Code: Phone Number:Supplier Address: Fax Number:Supplier Main Phone: E-mail Address:

Program Information Part InformationSRG Plant Part DescriptionCustomer Part Weight (Lbs)Program Name Part Dimensions LXWXH (mm)Model Year Part Number(s)Annual Volume Replaces part number

Packaging InformationPrimary Packaging ( Container ) Secondary Packaging(Unit Shipping Load)

1 Density ( Quantity of parts)2 Loaded weight ( Lbs - full)3 Outside Dimensions L X W X H (mm)4 Packaging Strategy (Expendable/Returnable)5 Packaging Code6 Material Type7 Cover / Top Cap8 Board9 Securement / Closure Type ( Tape, Stretch Wrap,…)

10 Dunnage & Description ( Divider, Corner supports,...)11 Labels ( Quantity/ Location)12 Compliant to SRG Specification's13 Reason for deviation14 Preliminary or Final

Part Only Part + Dunnage + Primary Bax Pallet Load (as it will be shipped)

Packaging CostPrice Manufacturer

Primary PackagingSecondary PackagingPackage $ Price / Part

Freight InformationStreet City State Zip Code

Shiping LocationShipping Hours Mileage from shipping location to SRG PlantCombining Loads List all part numbers being shippedShipment(s) / week Returnable or ExpendableParts/ Shipment Transportation ModeCost per shipment Freight cost per part

Comments :

Supplier Signature: Date: Comments:

Customer Approval Date: Comments:

DIGITAL IMAGES

C O S T

FREIGHT






Completed Sub Supplier PPAP Submission Checklist Yes No N/A

1 Sub Supplier has completed all PPAP requirements. Comments:

2 Sub Supplier PPAP's have been approved with in the past year. Comments:3 Sub Supplier is ISO 9000 or equivalent certified. Comments:

4 The Run@Rate or equivalent process trial run has been completed and has demonstrated the sub supplier's ability to meet all quoted capacity and quality requirements. (Validated by the supplier) Comments:

5 All Sub Supplier PSW documentation is included with in this PPAP. Comments:

6 The supplier has verified that their Sub Suppliers have met allrequirements on the print.Comments:

N/A 0

NO - REJECTED 0







Completed Tooling information and identification Checklist Yes No N/A

1 Correct tooling information completed and included with PPAP? Comments:

2 Photos of the tool included with the PPAP submission? Comments:3 Tools properly identified with permanent ownership tags and are photos included? Comments:

4 Materials used in tool contruction are as stated in the quotation? Comments:

5 Tooling costs are as stated in the quotation submitted? Comments:

6 Bailee Form fully completed, signed and included in the PPAP? Comments: All Tooling information must be returned including the signed Bailee form in order for PPAP approval to be given.

N/A 0

NO - REJECTED 0


Adobe Acrobat Document

Customer # Supplier :Program : Contact :Date : Phone :Part Description :

Material Specification :

Material currently been used :

I Press:1 Original tool manufacturer

2 Attached Tooling Drawing :

3 Type of press(rotary/flatbed)

4 Size of press (ie…7”, 10”)

II Tooling information1 Number of cavities across

2 Number of cavities around

3 Rout depth(Blade height)

4 Gear ratio

5 Gear pitch (ie..1/8”, 1/32”)

6 Shaft diameter

III Cutting style1 Metal to metal cut ( y/n)

2 Control dept cut (y/n)

3 Multi level (y/n)

IV Steel Rule

V Additional Information1 Identification Plate ( Property Of :)

Part number:

Eng. Level:

2 Tool Drawing :

3 Secondary Tooling:

4 Others :

History of maintenance that has been done on the tool in the past 12 Months :

Quality History :

Print Name : Signature :

DIE CUT TOOLING SUMMARY SHEET

If flat bed cutting, what is the size of The steel rule tooling ?( x” by x”)

(Still complete above)

Customer # Supplier :

Contact :

Phone :

Date : Email :

Part Description :

Component Material Specification / Material currently been used :

SRG Global GAPN Numbers

Programs

1 Tool Size : L X W X H

2 Tool Weight (lbs):

3 Number of Cavities :

4 Mould Type :

5 Runner System :

6 Gating Style :

7 Press Type & Size :

8 Type of Cooling System :

9 Type of Mechanisms :

(Slides / Lifters / Hydraulics / etc.)

10 Type of Tool Steel :

11 Cycle Time :

12 Part Weight :

13 Tooling Cost :

14 Capacity per 8 hrs :

15 Tool Condition:

16 Set-up Sheet :

(pressures, temperatures, times, etc.)

17 Identification Plate ( Property Of :)

Part number:

Eng. Level:

18 Tool Drawing :

19 Secondary Tooling:

20 Others :

History of maintenance that has been done on the mould :

Quality History :

Print Name : Signature :

COMPONENT TOOLING SUMMARY SHEET

PRELIMINARY DATE:__________________ CUSTOMER#________________ ASSY.#______________

S/O#___________ REVISION DATE:_____________ PART NAME CUSTOMER:____________________

MATERIAL PART NUMBER DESCRIPTION QUANTITY ECR NUMBER DATED

TYPE: MIN - MAX x WIDTH x PITCH

SIZE: _____________________________________

GROSS WEIGHT ____________________________

NET WEIGHT: ____________________________

OPERATION # DESCRIPTION OF OPERATION TOOL NUMBER TOOLING SIZE MACHINE REQUIREMENTS PCS PER HOUR PRESS / HOURS

INSPECTION:

PACKAING: SPECIFICATIONS: ___________________________ TOOLING SOURCE: __________________________________

CONTAINER TYPE: GAGE SOURCE: __________________________________

STANDARD PACK: S/O NUMBER: __________________________________

PALLET SIZE: ___________________________ CUSTOMER #: __________________________________

Tooling Process Information Checklist Requirements Element Documentation Checklist

Photos of the tools opened up to show station detailsEngineering drawings, both detail and assembly, for the tools. What format (CAD files – if so which software, pdf, hard copy)?What is the shut height of the toolsWhat are the current tool production run rates How many parts have been produced off the toolsWhat are the tonnage capacities of the presses the tools are currently inWhat is the actual tonnage required to run the toolsWhat is the physical size of the tools?What is the weights of the tool?What tool materials are used for the punches and dies?Are there any current outstanding deviations for the parts?Are there any material forming related issues?Have PPAP’d parts been produced and approved from these tools?Is inspection data available for review to assess capability and potential future concerns?Are dimensional layouts of the parts available for review?Who designed and built the tools?Is there any gaging included with the tools? Are any spare tooling components included with the tools?Are any sensors or controls integrated into the tools?Our P/N are to be stamped into the parts? Strokes per minute speedAny quality issues Save first and last parts off.Tools & Gauge tags “ Property of”Blank Size : L X W X ThBlank Weight





Supplier Contact Sheet and Manufacturing/Shipping Location Declaration

1 Correct Manufacturing Location Address Filled out? Comments:

2 Correct Ship From Location address Filled out? Comments:3 All Contacts Listed as required on the SRG Global Form? Comments:

4 Form singed by the Supplier Authorized Agent? Comments: This form must be fully completed and signed by the supplier representative before PPAP approval is granted. Form is embedded as a file in the next tab labeled "tab 26 Form."

Date Reviewed SReviewed by S


Part Number

Description

Rev. Level

Completed Yes No N/A

S 1 Correct Manufacturing Location Address Filled out?

Comments: Comments:

Correct Ship From Location address Filled out? S 2 Correct Ship From Location address Filled out?Comments: Comments:All Contacts Listed as required on the SRG Global Form? 3 All Contacts Listed as required on the SRG Global Form?Comments: Comments:

S 4 Form singed by the Supplier Authorized Agent?Comments: Comments:

This form must be fully completed and signed by the supplier representative before PPAP approval is This form must be fully completed and signed by the supplier representative before PPAP approval is

N/A 0

NO - REJECTED 0Date Reviewed

COMPLETED 0 Reviewed by

granted. Form is embedded as a file in the next tab labeled "tab 26 Form."

SAMPLE FORM COMPLETION GUIDELINES

Headers are linked to checksheet Supplier same

same Submission Date same

same PPAP Level same

CompletedSupplier Contact Sheet and Manufacturing/Shipping Location Declaration Yes

Correct Manufacturing Location Address Filled out?Comments:

Correct Ship From Location address Filled out?Comments:All Contacts Listed as required on the SRG Global Form?Comments:

Form singed by the Supplier Authorized Agent?Comments: This form must be fully completed and signed by the supplier representative before PPAP approval is

N/A

NO - REJECTEDSS COMPLETED


granted. Form is embedded as a file in the next tab labeled "tab 26 Form."

same

same

same

CompletedNo N/A

Comments:

Comments:

Comments:

Comments:

This form must be fully completed and signed by the supplier representative before PPAP approval is

N/A 0

NO - REJECTED 0

COMPLETED 0

Tab 26

Supplier Contact List and Manufacturing Location Declaration

Supplier Name

DUNS Number

Mailing Address

Manufacturing Address

Ship From Address

Contact Name Position Phone Fax Cell Email

Customer

Primary

Secondary

Scheduling

Primary

Secondary

Shipping

Primary

Secondary

Quality

Primary

Secondary

Engineering

Primary

Secondary

After Hours

Primary

Secondary

Management

Primary

Secondary

I certify that the above listed manufacturing location and shipping location is in accordance with the quote submitted to SRG Global Purchasing.

Supplier Representative Signature:

SRG Director of Purchasing/Buyer Signature:

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